Motor

ABSTRACT

A yoke of a motor has a bottom and an open end and accommodates an armature. An end bracket substantially closes the open end of the yoke. A connector portion, which bulges outward of the yoke, and a cutout portion are formed in the circumferential wall of the end bracket. A pair of feed members is provided to extend from the interior of the end bracket to the connector portion through the cutout portion. The end bracket has an accommodation recess for accommodating the noise suppression element at a position corresponding to the cutout portion. Each feed member has an accommodation recess corresponding portion, which corresponds to the accommodation recess, and a cutout portion corresponding portion, which corresponds to the cutout portion. The distance between the accommodation recess corresponding portions of the feed members is greater than the distance between the cutout portion corresponding portions.

BACKGROUND OF THE INVENTION

The present invention relates to a motor in which noise suppression elements can be installed.

Conventionally, a type of motor has been known that includes an armature, a substantially cylindrical yoke that has a bottom and an open end and rotationally receives an armature, an end bracket secured to substantially close the open end of the yoke, and noise suppression elements such as capacitors provided in the end bracket. For example, the motor disclosed in Japanese Laid-Open Patent Publication No. 2009-112095 has a connector portion formed on a part of the circumferential wall of the end bracket. The connector portion bulges outward from the yoke when viewed in the axial direction. A cutout portion is formed in a part of the circumferential wall of the end bracket that corresponds to the connector portion. The cutout portion allows the interior of the end bracket to communicate with the connector portion. A pair of feed members extends from the interior of the end bracket to the connector portion through the cutout portion. The feed members have a pair of cutout portion corresponding portions, which correspond to the cutout portion. Noise suppression elements are located between the cutout portion corresponding portions. The terminals of the noise suppression elements are drawn outward in the radial direction and connected to the feed members at the connector portion.

However, in the motor described above, the noise suppression elements are located between the cutout portion corresponding portions, which correspond to the cutout portion of the feed members. Therefore, the width of the cutout portion (discontinued part of the circumferential wall), at which the cutout portion corresponding portions are located, is increased. At this part, the strength of the end bracket is reduced. Therefore, to ensure the strength of the end bracket, the thickness of the end bracket needs to be increased in parts in the vicinity of a cutout portion.

Accordingly, it is an objective of the present invention to provide a motor that has a cutout portion with a reduced width and therefore easily ensures the strength of an end bracket.

To achieve the foregoing objective and in accordance with one aspect of the present invention, a motor including an armature, a substantially cylindrical yoke, and an end bracket is provided. The yoke has a bottom and an open end. The yoke rotationally accommodates the armature. The end bracket is fixed to the yoke to substantially close the open end of the yoke. The end bracket has a radial direction, a circumferential direction, and an axial direction. A connector portion is formed in a part of a circumferential wall of the end bracket, the connector portion bulging outward from the yoke as viewed in the axial direction. A cutout portion is formed in a part of the circumferential wall of the end bracket that corresponds to the connector portion. The cutout portion allows the interior of the end bracket to communicate with the connector portion. A pair of feed members is provided to extend from the interior of the end bracket to the connector portion through the cutout portion. A pair of terminals of a noise suppression element can be connected to the feed members, respectively. The end bracket has an accommodation recess for accommodating the noise suppression element at a position corresponding to the cutout portion. The circumferential width of the accommodation recess is greater than the circumferential width of the cutout portion. Each feed member has an accommodation recess corresponding portion, which corresponds to the accommodation recess, and a cutout portion corresponding portion, which corresponds to the cutout portion. The distance between the accommodation recess corresponding portions of the feed members is greater than the distance between the cutout portion corresponding portions.

Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:

FIG. 1A is a partial plan view illustrating a motor according to one embodiment of the present invention;

FIG. 1B is a cross-sectional view taken along line 1B-1B in FIG. 1A;

FIG. 2 is a partial plan view showing the motor of FIG. 1A before a rotational speed detecting member is installed;

FIG. 3 is a partial plan view for explanatory illustration of the end bracket in the motor of FIG. 1A;

FIGS. 4A to 4D are explanatory diagrams showing the feed members in the motor of FIG. 1A;

FIG. 5A is a partial plan view illustrating a motor of a different specification; and

FIG. 5B is a cross-sectional view taken along line 5B-5B in FIG. 5A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

One embodiment of the present invention will now be described with reference to the drawings.

As shown in FIGS. 1A and 1B, a motor 1 includes a substantially cylindrical yoke 2, which has a bottom and an open end, and an end bracket 3, which is fixed to substantially close the open end of the yoke 2. The yoke 2 is made of magnetic metal. Magnets, which are not illustrated, are fixed to the inner circumferential surface of the yoke 2. An armature is accommodated in the yoke 2. A rotary shaft 4 of the armature is rotationally supported by a bearing 5 held at the bottom of the end bracket 3 and an unillustrated bearing, which is held substantially at the center of the bottom of the yoke 2, that is, a center of an end face opposite to the open end. In addition to a core about which coils are wound, a commutator and a sensor magnet 6 (refer to FIG. 1B) are fixed to the rotary shaft 4. As shown in FIG. 1B, the sensor magnet 6 of the present embodiment is fixed to the rotary shaft 4 at a position that is displaced from the bearing 5 in the axial direction and in the vicinity of the bearing 5.

The end bracket 3 is made of plastic and is shaped as a cylinder having a bottom and an open end corresponding to the open end of the yoke 2. A through hole 3 a is formed through a center of the bottom of the end bracket 3 in the axial direction to receive the distal end of the rotary shaft 4. The bearing 5 is held at a part of the through hole 3 a that is closer to the interior of the yoke 2. The distal end of the rotary shaft 4 is coupled to a coupler portion (not shown) of a load.

A connector portion 3 b is integrally formed with a part of the circumferential wall of the end bracket 3. The connector portion 3 b bulges outward of the yoke 2 when viewed in the axial direction of the rotary shaft 4, that is, in the axial direction of the end bracket 3. A cutout portion (discontinued part of the circumferential wall) is formed in a part of the circumferential wall of the end bracket 3 that corresponds to the connector portion 3 b. The cutout portion allows the interior of the end bracket 3 to communicate with the connector portion 3 b. The connector portion 3 b has a cylindrical portion 3 d. The cylindrical portion 3 d extends in the axial direction to receive an external connector of a control device (not shown), which serves as a power source device. In FIG. 1B, the cylindrical portion 3 d extends upward along the yoke 2.

As shown in FIG. 3, the end bracket 3 has an accommodation recess 3 e at a position corresponding to the cutout portion 3 c. The width of the accommodation recess 3 e in a direction perpendicular to the radial direction, that is, in the circumferential direction, is greater than that of the cutout portion 3 c. The accommodation recess 3 e is formed substantially as a rectangle, which is formed by parallel two sides extending in the radial direction as viewed in the axial direction and another two sides extending in a direction perpendicular to the radial direction to connect the first two sides. The accommodation recess 3 e is recessed in the axial direction, or a in a direction away from the viewer of FIG. 3.

As shown in FIG. 1A, the end bracket 3 has a pair of feeder brushes, which is located inward of the yoke 2 as viewed in the axial direction and held to be movable in the radial direction. In the present embodiment, the pair of feeder brushes includes first and second feeder brushes 11, 12. The end bracket 3 has an unillustrated torsion coil spring, which urges and presses the feeder brushes 11, 12 radially inward against the commutator. As shown in FIGS. 2 and 3, the end bracket 3 has a pair of feed members, or first and second feed members 21, 22. The first and second feed members 21, 22 are electrically connected to the feeder brushes 11, 12, respectively, and extend, as viewed in the axial direction, from the interior of the yoke 2 to the connector portion 3 b (the cylindrical portion 3 d) through the cutout portion 3 c.

Specifically, a pigtail 11 a of the first feeder brush 11 is connected to the first feed member 21 via a choke coil 23 and a plate-like thermistor 24 as shown in FIGS. 4A and 4B. A pigtail 12 a of the second feeder brush 12 is connected to the second feed member 22 via a choke coil 25 as shown in FIGS. 4C and 4D. As shown in FIGS. 2 and 3, the feed members 21, 22 has accommodation recess corresponding portions 21 a, 22 a, which correspond to the accommodation recess 3 e, and cutout portion corresponding portions 21 b, 22 b, which correspond to the cutout portion 3 c. The feed members 21, 22 extend to the cylindrical portion 3 d of the connector portion 3 b. At the distal ends, the feed members 21, 22 have connection terminal portions 21 c, 22 c extending in the axial direction and along the cylindrical portion 3 d. With the feed members 21, 22 installed in the end bracket 3 as shown in FIGS. 2 and 3, the distance between the accommodation recess corresponding portions 21 a, 22 a is greater than the distance between the cutout portion corresponding portions 21 b, 22 b. Further, as shown in FIGS. 1B and 3, with the feed members 21, 22 installed in the end bracket 3, the accommodation recess corresponding portions 21 a, 22 a are flush with inner surfaces 3 f of the accommodation recess 3 e, which face each other in the width direction. As shown in FIG. 1B, axial ends (lower ends as viewed in FIG. 1B) of the accommodation recess corresponding portions 21 a, 22 a are arranged to contact in the axial direction opening edge (the upper end as viewed in FIG. 1B) of the accommodation recess 3 e of the end bracket 3. The accommodation recess corresponding portions 21 a, 22 a at least partly overlap with the bearing 5 in the axial direction (see FIG. 1B).

First and second noise suppression elements 31, 32 have a pair of terminals 31 a and a pair of terminals 32 a, respectively. Connection notches 21 d, 21 e, 22 d, 22 e, which serve as connection portions, are formed in the accommodation recess corresponding portions 21 a, 22 a of the feed members 21, 22. The terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 are connected to the connection notches 21 d, 21 e, 22 d, 22 e. Specifically, the accommodation recess corresponding portions 21 a, 22 a have the connection notches 21 d, 21 e, 22 d, 22 e, each of which receives one of the terminals 31 a, 32 a of the noise suppression elements 31, 32. The connection notches 21 d, 21 e, 22 d, 22 e are arranged in parallel in the radial direction of the feed members 21, 22. The connection notches 21 d, 21 e, 22 d, 22 e of the present embodiment have shapes capable of receiving in the axial direction the terminals 31 a, 32 a of the first and second noise suppression elements 31, 32.

The first noise suppression element 31 of the present embodiment is formed by a pair of combined capacitors 31 b. The capacitors 31 b are held by a holding member 31 c such that the flat surfaces thereof face each other. Each capacitor 31 b has first and second terminals. The first terminals are connected to the holding member 31 c. The second terminals are drawn in the direction opposite to the facing direction and function as terminals 31 a for external connection of the first noise suppression element 31. A ground terminal 31 d is formed in the holding member 31 c. With the first noise suppression element 31 installed in the end bracket 3, the ground terminal 31 d is tightly held between the end bracket 3 and the yoke 2. The second noise suppression element 32 of the present embodiment is formed by a single varistor. The main body of the second noise suppression element 32 except for the terminals 32 a can be arranged between the flat surfaces the capacitors 31 b.

Each of the connection notches 21 d, 21 e, 22 d, 22 e has a width (in the radial direction) that corresponds to the size of the corresponding one of the terminals 31 a, 32 a of the noise suppression elements 31, 32. Also, the widths of the connection notches 21 d, 21 e, 22 d, 22 e are determined to allow the terminals 31 a, 32 a to be press fitted in the connection notches 21 d, 21 e, 22 d, 22 e. The connection notches 21 d, 21 e, 22 d, 22 e are formed in the feed members 21, 22 to extend in the axial direction, and open in one end in the axial direction of the feed members 21, 22. The width of the opening of each connection notches 21 d, 21 e, 22 d, 22 e widens toward the open end. The first and second noise suppression elements 31, 32 are accommodated in the accommodation recess 3 e as shown in FIGS. 1B and 2. In this state, the terminals 31 a, 32 a are press fitted in and supported by the connection notches 21 d, 21 e, 22 d, 22 e to be electrically connected to the connection notches 21 d, 21 e, 22 d, 22 e.

As shown in FIGS. 5A and 5B, the connection notches 21 d, 22 d of the present embodiment have such shapes to which a terminal 41 a of a noise suppression element 41 in a motor having a different specification can be inserted (press-fitted). The noise suppression element 41 is formed by a single capacitor and is suitable for motors having inexpensive specifications without varistors.

As shown in FIGS. 1A and 1B, a rotational speed detecting member 51 is attached to the end bracket 3 at a position facing the sensor magnet 6 in the radial direction. The rotational speed detecting member 51 detects changes in the magnetic force of the sensor magnet 6, that is, the number of rotations of the rotary shaft 4.

Specifically, the rotational speed detecting member 51 includes a plastic base member 51 a, a pair of sensor terminals 51 b insert molded in the base member 51 a, and a Hall IC 51 c mounted on a substrate 51 d. The substrate 51 d is fixed to the base member 51 a. As shown in FIG. 1B, the rotational speed detecting member 51 is located at a position displaced in the axial direction from the accommodation recess corresponding portion 22 a (21 a). As shown in FIG. 1A, the rotational speed detecting member 51 substantially covers the accommodation recess 3 e (the first and second noise suppression elements 31, 32) as viewed in the axial direction. The Hall IC 51 c (the substrate 51 d) is located in a part of the rotational speed detecting member 51 that faces the sensor magnet 6 (the center axis).

The rotational speed detecting member 51 has an extension 51 e, which extends to the connector portion 3 b through the cutout portion 3 c. When the rotational speed detecting member 51 is installed in the end bracket 3, the extension 51 e is located at a position displaced in the axial direction from the cutout portion corresponding portions 21 b, 22 b of the feed members 21, 22 and overlaps the cutout portion corresponding portions 21 b, 22 b as viewed in the axial direction. The sensor terminals 51 b are embedded in the extension 51 e. A first end of each sensor terminal 51 b is connected to the substrate 51 d. A second end of each sensor terminal 51 b protrudes in the axial direction together with (parallel with) the connection terminal portions 21 c, 22 c of the feed members 21, 22 in the cylindrical portion 3 d. When an external connector is plugged into the cylindrical portion 3 d, the second ends of the sensor terminals 51 b are connected to the control device together with the connection terminal portions 21 c, 22 c.

Operation of the motor 1 will now be described.

When the external control device supplies a drive current to the coils of the armature via the feed members 21, 22, the feeder brushes 11, 12, and the commutator, the armature is rotated. When the sensor magnet 6 rotates together with the rotary shaft 4 of the armature, the accompanying change in the magnetic force is detected by the rotational speed detecting member 51 (the Hall IC 51 c), a signal corresponding to the number of rotations of the rotary shaft 4 is output to the control device. Various control processes are executed in accordance with the signal. During the operation, the first and second noise suppression elements 31, 32 connected to the feed members 21, 22 remove noise.

The above described embodiment has the following advantages.

(1) A cutout portion is formed in a part of the circumferential wall of the end bracket 3 that corresponds to the connector portion 3 b. The cutout portion allows the interior of the end bracket 3 to communicate with the connector portion 3 b. The accommodation recess 3 e for accommodating the first and second noise suppression elements 31, 32 is formed at a position in the end bracket 3 that corresponds to the cutout portion 3 c. The width of the accommodation recess 3 e in a direction perpendicular to the radial direction, that is, in the circumferential direction, is greater than that of the cutout portion 3 c.

With the feed members 21, 22 installed in the end bracket 3, the distance between the accommodation recess corresponding portions 21 a, 22 a, which correspond to the accommodation recess 3 e, is greater than the distance between the cutout portion corresponding portions 21 b, 22 b, which correspond to the cutout portion 3 c. According to this configuration, compared to a conventional motor, in which noise suppression elements are located between cutout portion corresponding portions, which correspond to cutout portions of feed members, the strength of the end bracket 3 is easily ensured while reducing the width of the cutout portion 3 c (discontinued part of the circumferential wall) to reduce the thickness, for example, of the end bracket 3.

(2) With the feed members 21, 22 installed in the end bracket 3, the accommodation recess corresponding portions 21 a, 22 a are flush with inner surfaces 3 f, which are arranged in the width direction of the accommodation recess 3 e. The connection notches 21 d, 21 e, 22 d, 22 e are formed in the accommodation recess corresponding portions 21 a, 22 a. The terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 are connected to the connection notches 21 d, 21 e, 22 d, 22 e. Thus, the terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 can be shortened and easily connected. That is, since the accommodation recess corresponding portions 21 a, 22 a of the feed members 21, 22 are arranged to extend the inner surfaces 3 f of the accommodation recess 3 e in the axial direction, the accommodation recess 3 e is not narrowed due to the accommodation recess corresponding portions 21 a, 22 a. The terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 accommodated in the accommodation recess 3 e do not need to prolonged to each the connection notches 21 d, 21 e, 22 d, 22 e of the accommodation recess corresponding portions 21 a, 22 a, and the terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 can be easily connected.

(3) A plurality of parallel connection notches 21 d, 21 e, 22 d, 22 e are formed in the radial direction in the accommodation recess corresponding portions 21 a, 22 a of the feed members 21, 22. The terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 are connected to the connection notches 21 d, 21 e, 22 d, 22 e. Therefore, when the first and second (a plurality of) noise suppression elements 31, 32 are located between the feed members 21, 22, the terminals 31 a, 32 a of the first and second (a plurality of) noise suppression elements 31, 32 can be easily connected to each other. The terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 do not need to be extended, but can be shortened.

(4) The accommodation recess corresponding portions 21 a, 22 a are located at positions where the axial dimensions thereof are equal to that of the bearing 5, and displaced axially from the position of the rotational speed detecting member 51. Therefore, the accommodation recess corresponding portions 21 a, 22 a do not need to be formed to avoid (detour) the rotational speed detecting member 51 as viewed in the axial direction. This allows the feed members 21, 22 to be shortened.

(5) In the rotational speed detecting member 51, the extension 51 e, which extends to the connector portion 3 b via the cutout portion 3 c, is located at a position axially displaced from the positions of the cutout portion corresponding portions 21 b, 22 b of the feed members 21, 22. Therefore, the cutout portion corresponding portions 21 b, 22 b do not need to be formed to avoid (detour) the extension 51 e as viewed in the axial direction. This allows the width of the cutout portion 3 c (discontinued part of the circumferential wall) to be further reduced. Thus, the strength of the end bracket 3 is easily ensured while reducing the thickness, for example, of the end bracket 3.

The above described embodiment may be modified as follows.

In the above illustrated embodiment, the accommodation recess corresponding portions 21 a, 22 a of the feed members 21, 22 are flush with the inner surfaces 3 f, which are arranged in the width direction of the accommodation recess 3 e. However, the present invention is not limited to this configuration. The accommodation recess corresponding portions 21 a, 22 a may be displaced from the inner surfaces 3 f as viewed in the axial direction.

In the above illustrated embodiment, a plurality of (two) parallel connection notches 21 d, 21 e, 22 d, 22 e are formed in the radial direction in the accommodation recess corresponding portions 21 a, 22 a. However, the present invention is not limited this configuration. For example, only one connection notch (connection portion) may be formed in each of the accommodation recess corresponding portions 21 a, 22 a. In this case, only one noise suppression element can be provided (connected). Also, the number of connection notches (connection portions) in the motor may be increased, so that three or more noise suppression elements can be provided.

In the above illustrated embodiment, the accommodation recess corresponding portions 21 a, 22 a are located at positions where the axial dimensions thereof are equal to that of the bearing 5, and displaced axially from the position of the rotational speed detecting member 51. However, the present invention is not limited to this. That is, the accommodation recess corresponding portions 21 a, 22 a may be located at positions that are aligned with the rotational speed detecting member 51 in the axial direction.

In the rotational speed detecting member 51, the extension 51 e, which extends to the connector portion 3 b via the cutout portion 3 c, is located at a position axially displaced from the positions of the cutout portion corresponding portions 21 b, 22 b of the feed members 21, 22. However, the present invention is not limited to this. That is, the extension 51 e may be located at a position that is aligned with the cutout portion corresponding portions 21 b, 22 b in the axial direction.

In the above embodiment, the connection portions are formed by the connection notches 21 d, 21 e, 22 d, 22 e, into which the terminals 31 a, 32 a of the first and second noise suppression elements 31, 32 can be inserted in the axial direction. However, connection portions having different shapes may be used as long as connection terminals are designed to receive terminals.

In the above described embodiment, the widths of the connection notches 21 d, 21 e, 22 d, 22 e are determined such that the terminals 31 a, 32 a can be press fitted in the corresponding the connection notches 21 d, 21 e, 22 d, 22 e. However, the present invention is not limited to this configuration. That is, the width may be determined such that the terminals 31 a, 32 a can be press fitted into part of the connection notches. For example, the widths of the connection notches may be determined such that the terminals 31 a, 32 a cannot be press fitted in any of the connection notches. In a case where press fitting cannot be performed, soldering needs to be performed, instead. 

What is claimed is:
 1. An armature; a substantially cylindrical yoke having a bottom and an open end, the yoke rotationally accommodating the armature; and an end bracket that is fixed to the yoke to substantially close the open end of the yoke, the end bracket extending in a radial direction, a circumferential direction, and an axial direction, wherein a connector portion is formed in a part of a circumferential wall of the end bracket, the connector portion bulging outward from the yoke as viewed in the axial direction, a cutout portion is formed in a part of the circumferential wall of the end bracket that corresponds to the connector portion, wherein the cutout portion allows the interior of the end bracket to communicate with the connector portion, a pair of feed members is provided to extend from the interior of the end bracket to the connector portion through the cutout portion, wherein a pair of terminals of a noise suppression element are operative to be connected to the feed members, respectively, the end bracket has an accommodation recess for accommodating the noise suppression element at a position corresponding to the cutout portion, wherein the circumferential width of the accommodation recess is greater than the circumferential width of the cutout portion, and each feed member has an accommodation recess corresponding portion, which corresponds to the accommodation recess, and a cutout portion corresponding portion, which corresponds to the cutout portion, wherein the cutout portion corresponding portions are arranged within a circumferential range formed by the pair of feeder accommodation recess corresponding portions with respect to the rotor axis, and the distance between the accommodation recess corresponding portions of the feed members is greater than the distance between the cutout portion corresponding portions, wherein, each feed member of the pair of feed members includes a single arm portion comprising a first distal end, a second distal end, a first bend and a second bend, the accommodation recess corresponding portion is arranged on the single arm between the first distal end and the second distal end along the length of the single arm portion, each accommodation recess corresponding portion has a connection portion, to which one of the terminals of the noise suppression element is connected each of the feed members extending from the connector portion through the cutout portion to the first bend and extending from the first bend along the circumferential wall to the second bend, and extending from the second bend through the accommodation recess, such that the cutout portion corresponding portions of the feed members are circumferentially offset from the accommodation recess corresponding portions.
 2. The motor according to claim 1, wherein the accommodation recess corresponding portions are formed to be flush with a pair of inner surfaces facing each other in the width direction of the accommodation recess.
 3. The motor according to claim 1, wherein each accommodation recess corresponding portion has a plurality of connection portions, wherein each of a pair of terminals of each of a plurality of noise suppression elements is connected to each connection portion, and the connection portions are formed in the feed member and arranged in the radial direction.
 4. The motor according to claim 1, wherein the end bracket holds a bearing for supporting a rotary shaft of the armature, a sensor magnet is fixed to the rotary shaft at a position displaced in the axial direction from the bearing, a rotational speed detecting member is attached to the end bracket at a position facing the sensor magnet in the radial direction, the rotational speed detecting member is capable of detecting changes in the magnetic force of the sensor magnet, and the accommodation recess corresponding portion at least partly overlaps with the bearing in the radial direction and is displaced from the rotational speed detecting member in the axial direction.
 5. The motor according to claim 4, wherein the rotational speed detecting member has an extension that extends to the connector portion via the cutout portion, and the extension is located at a position displaced in the axial direction from the cutout portion corresponding portions of the feed members. 